Air Door Position Sensor / Switch: Service and Repair
Door Motors
Air Flow Door Motor Position Sensor
Removing
- Remove air intake housing with air flow door. Refer to=> [ Air Intake Shroud with Air Flow Door ].
• Mark motor/door connecting elements when removing danger of swapping with connecting elements of the other actuator motors.
• In the event of fault "Upper or lower limit value exceeded", check connecting element of engine/door, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element.
- Remove bolts - A -.
- Remove the grommet - C - from the mount.
- Remove control motor.
- Disconnect harness connector from actuator - B -.
Installing
- Check back pressure door position before installing actuator.
- Remove the connecting piece - A - from the back pressure flap shaft and position it on the actuator - B - as illustrated.
• Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied to terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if connecting element - B - is attached.
• If connecting element - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned.
• If shaft is so awkwardly positioned that connecting element cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery using adapter lead. Refer to=> [ Control Motor Actuation Adapter Cables ] Testing and Inspection or an adapter lead from Connector Test Kit (V.A.G 1594/C).
• Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.
• Check seating of connecting element, there must be no play between actuator mount and connecting element.
- Install the connecting piece - A - on the back pressure flap shaft.
- Install actuator - B -.
- Hand-tighten mounting bolts - A - (10 Nm).
- Before installing cover, check correct positioning of connector - B -, routing of wiring as illustrated and position of grommet - C -.
- Seal the grommet where the wiring harness is routed under the cover to the actuator with Silicone Sealant (D 176 001 A3) to prevent water from entering the grommet and reaching the connector or actuator.
- Install the removed components again in reverse order.
- Check the DTC memory for the Climatronic Control Module (J255) A/C control head and erase any faults displayed if necessary Vehicle diagnosis, testing and information system VAS 5051 in the "Guided Fault Finding" function.
- Perform a basic setting and output diagnostic test mode on the A/C system Vehicle diagnosis, testing and information system VAS 5051 in the "Guided Fault Finding" function.